Suzuki RM250 Two Stroke Engine Tear Down - STEP BY STEP HOW TO

This video is a complete HOW TO video of tearing down a Suzuki RM250 Two stroke dirt bike engine. It is a full disassembly of the entire motor. This was definitely an interesting tear down as I was hit with surprise after surprise and road block after road block it felt! It is a step by step procedure on how to tear the motor apart. If you guys have any questions or tips for me for my next engine tear down, leave a comment below!
All tools are linked in this description!
🔥2006 RM250 Manual: www.ebay.com/itm/2006-Suzuki-...
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Looking for parts and tools?! Rocky Mountain will no doubt have them in stock. Check out the links below for all of the products used in the video. I greatly appreciate your support when you do that!
🔥RMATV/MC OEM Parts: www.rockymountainatvmc.com/oe...
🔥MOTION PRO TORQUE WRENCH ADAPTER: www.rockymountainatvmc.com/pa...
🔥MAXIMA 80W MTL TRANSMISSION OIL: www.rockymountainatvmc.com/pa...
🔥MAXIMA COOLANOL: www.rockymountainatvmc.com/pa...
🔥MAXIMA QUICK MIX CUP: www.rockymountainatvmc.com/pa...
🔥MAXIMA SUPER M PREMIX: www.rockymountainatvmc.com/pa...
🔥RATIO RITE MEASURING CUP: www.rockymountainatvmc.com/pa...
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🔥DIGITAL CALIPER MEASURING TOOL: www.rockymountainatvmc.com/pa...
🔥TUSK STEERING STEM BEARING INSTALLER: www.rockymountainatvmc.com/pa...
🔥TUSK CLUTCH HOLDER: www.rockymountainatvmc.com/pa...
🔥TUSK CRANKCASE SPLITTER: www.rockymountainatvmc.com/pa...
🔥TUSK FLYWHEEL PULLER: www.rockymountainatvmc.com/pa...
🔥TUSK CRANK PULLER/INSTALLER: www.rockymountainatvmc.com/pa...
🔥TUSK BEARING REMOVAL TOOL: www.rockymountainatvmc.com/pa...
🔥MOTION PRO STEERING BEARING RACE DRIVER: www.rockymountainatvmc.com/pa...
🔥BENCH BUFFER: amzn.to/3tEmFG1
🔥PRYME CLEANING WHEEL PACK - 8 Inch: www.prymemx.com/collections/b...
PRYME FIBER FLAP WHEEL PACK: www.prymemx.com/collections/b...
🔥DREMEL: amzn.to/3lJal4L
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Use GREG10 to save at PHATHEAD RACING HEADS: lukesracing.com/Merchant2/mer...
This video is NOT sponsored. Some product links are affiliate links which means if you buy something I'll receive a small commission. Thank you for supporting the channel!

[@jonakselfosskaug4596]

This is much better then Netflix.

[@GregHitchko]

Haha hell yeah! That's awesome, well I've got a whole library for you to check out. Thanks!

[@demel6460]

I don’t usually comment on videos but this is probably the best how to I’ve seen I didn’t have any questions and got my rm250 torn apart first try

[@GregHitchko]

Thank you for the feedback my man, means a lot! Stoked you were able to get your engine torn down without issues. I still need the edit the rebuild but not quite sure when I will get to that!

[@demel6460]

@@GregHitchko I’m looking forward to it! I’ll watch for sure

[@davidpalmer287]

Great video. You can use your clutch holder to hold the primary gear to avoid putting the clutch on and using pennies.

[@dr650riderarkansas8]

Nothing like having the correct tools.

[@GregHitchko]

You can say that again haha

[@vincentconte6028]

clutch basket is toast

[@antssta]

About to swap my 21 crf 450 for an 07 rm 250 with cash my way! Thank you for doing this series bro

[@GregHitchko]

Nice!! 07 is definitely the way to go, hell of a find and trade brother.

[@TTR66]

Knowleged Dude&Quality Work Get's 💯%Support🤘

[@GregHitchko]

Right on! Thanks for that feedback dude, and always down to receive more to get better 🙌🏼

[@JourdonGulick]

Great quality breakdown 👌.

[@GregHitchko]

Thanks Jourdon, I appreciate that feedback man!

[@GabrielBoutros]

Amazing! Very interesting video!

[@GregHitchko]

Thanks Gabriel, much appreciated ✊🏼

[@lindenphilippson]

Another A+ video!

[@GregHitchko]

Right on, much appreciated Linden, that was a "fun" one haha

[@twostrokeracing7666]

Those wearmarks can be ground down if they are just at the surface. If they go any deeper get a new clutch basket. Greetings from Germany 🤙🏻

[@GregHitchko]

I am thinking I will need a new basket by the sounds and feel of it. Thanks for watching for Germany mate!

[@jerryblack8103]

good video man, but for stubborn kick starters use a small bearing or steering wheel puller and wd 40. 5 minutes and viola

[@TheSikkTACO]

you need to get yourself a impact wrench for the crank bolt, clutch and stator, will make life 1000 times easier

[@GregHitchko]

I need to grab a 1/2" drive one, the 3/8" inch drive didnt have enough juice!

[@TheSikkTACO]

@@GregHitchko i highly recommend checking out this channel to compare impact wrenches its a good watch, my go to 1/2 impact is my Milwaukee 2767-20 high torque impact wrench and my 3/8 2554-20 stubby, I haven't had a single bolt that my 1/2 couldn't take off. Hope this helps out kzbin.info/door/Zem9C5rWjSb0B8tV3k2EZg

[@justinboonzaier6730]

You can file down the fingers on the clutch basket,but your clutch basket doesn't look too bad,if it is very bad your clutch will start to drag.🤙👌

[@GregHitchko]

Right on! I will keep that in mind about the filing down. Basket wasn't terrible but not perfect. Thanks Justin!

[@JokeR-wl6yc]

Lets go lets go!!Cheerss!..

[@GregHitchko]

Thanks mate!

[@RRDfinland]

Thx for showing clutch side what parts supposed to be there i have 06 too

[@kingscum605]

Yo pb blaster all day lol and it smells great too!

[@GregHitchko]

I didn't have any at the time which is a fail on my part haha!

[@brycegrebner3977]

Idk if he tried this but if you got that kick start getting stuck issue, you can try putting a wrench behind it to pry “evenlier” as compared to the screw driver

[@Nahtanoj65]

Awesome break down, probably nice for you as well to go back to footage if you don't remember something on reassembly! Any advice if once you disassemble various engine stuff and find that bolts are stripped from a previous owner... asking for a friend lol

[@GregHitchko]

Oh yeah for sure! I try to make sure I get the details so I can go back and review it too for when i put it back together haha. What bolts happen to be stripped?? I just bought a socket set for stripped bolt heads off. I have a link in the video description! I am going to be putting out a video shortly on it.

[@Nahtanoj65]

@@GregHitchko I wish it was the bolt heads lol. Pretty much all related to a previous kips service. Over tightened bolts stripping out the head. One on the left side kips cover, the left power valve retaining bolt, and two for the cover that goes over the kips lever. Assuming would need to re tap the head. Using orange loctite for now since in each location the other bolts seem tight enough to keep things happy

[@GregHitchko]

@@Nahtanoj65 damnn I can see one bolt being a messed up but FOUR?? That's crazy man. I feel like a machine shop could take care of that professionally for you. And hopefully for not that much

[@Calikid42O]

That clutch basket is pretty notched so yes would be best to replace

[@GregHitchko]

Thanks for that confirmation dude! I was not feeling good about it

[@TheOffCycle]

Flywheel nut and primary bolt shoulda been broke loose b4 taking the top end off. Just put some rope down the spark plug hole to lock the crank up.

[@GregHitchko]

From now on, I will ALWAYS do it that way so i don't have to go through the struggle of getting it off afterward. Thanks my dude!

[@jonnoMoto]

Iirc, if the weight needed the spacer it's a 10oz. I used to have an 8oz and I don't remember it needing a spacer. Tbh, I couldn't notice much of a difference going from 8 to 10oz. Steahly didn't make a 12oz weight for that bike. Somewhere on their website they explain the weights they give.

[@GregHitchko]

When i put it back together, I'd love to compare the bike with and without the weight!

[@owenashby4572]

would this video work with my 2000 rm250? I'm new to suzuki so I haven't done a ton of research

[@chrisrieger9201]

Where did you get that service manual it’s awesome

[@GregHitchko]

You can buy a PDF on ebay for like 5 bucks or something and then you can just print out the sections you need!

[@stevenoram5139]

Hi Greg I just bought 2006 rm 250 bikes running lovely... But I noticed little hole above power valve at left side of engine just at back of power valve screw I thought maybe it's problem with cyclinder head but I see on yours you have same sort of hole where power valve bolt screws in.. Just wanted to know is it fine not seen it on all newer rm 250 bikes just wondering what little hole does as it looks like piece as broken out regards Steve

[@GregHitchko]

Hi Steven thanks for asking man. There should be two holes on top of where the power valve is on the cylinder that are vent holes. In those holes there should be an elbow piece that has a black vent tube that slides on to it. It is common for these bikes to lose those elbow pieces if they weren't installed correctly. I would go to Rocky Mountain and look at their OEM parts catalog to grab yourself one! And a hose that connects to it as well.

[@stevenoram5139]

@@GregHitchko hi gred I have 2 holes on top of power valve with 2 black tubes that's fine it's hole left side of engine but this side hole is open I thought it locked like piece of barrel have broken off barrel... but every 2006 barrel I've seen as same hole so was just abit worried thanks for reply I will have look at rocky mountain alot of stuff over in America.. Ive bought some stuff from America before but costs loads with duty tax and delivery but will check rocky mountain out.. Only seen few of your vids you done some amazing vids with rm kx yz and cr bikes keep good work up mate nice to see someone in to 2 strokes big time like yourself your bikes look stunning I just bought 2006 rm 250 wasn't cheap cost me £ 6000 but I knocked them down grand it's mint with all new billet talan gold acr wheels red hubs.. Full fmf pipe and load of other extras new bearing and full engine rebuild..wasnt cheap but nice bike I'll be keeping it forever only bikes I've ever had are rm 80 125 and 250 since kid so love rm bikes my favourite bikes and miss my 91 rm 125 aswell that was awesome bike... thanks for your reply and help greg I will look in to it Kind regards Steve. 👍👍

[@Drain09]

Same bike and same problem with kickstarter. I tried heat and penetrating lube with no success would only come half way off. Had to take cover off and then beat the shaft out. Ended up being galled splines somehow so had to file them down to make fit again. Took a couple hrs and was ridiculous. Was definitely frustrating and wanted to quit. My 06 RM250 keeps having nothing but gremlins. Hoping it’s worth it when all said and done.

[@GregHitchko]

Dudeee that sounds way worse than what I went through. But I hear you man, something that is supposed to take 30 seconds takes 2 hours. Wicked frustrating!

[@JM-wy6sq]

Looks like you opened up a can of worms towards the end there 😅

[@TherealWinterpillow]

What snap ring pliers do you use?

[@GregHitchko]

My set is actually from harbor freight which I don't recommend, I would try and snag a well known brand set. The HF ones don't work that well.

[@chrisrieger9201]

For trail riding is the phat head better than stock head?

[@gumpycognac4505]

Higher compression is the exact opposite of what you would normally want for trail riding. Higher compression needs better gas and more cooling (air flow through radiators) just my basic idea

[@bfoote1989]

I have transmission fluid going I to cylinder and into exhaust and it's not a small amount any Idea? 2001 rm 250

[@johnmendivil6320]

Same problem and year too

[@abelvelazco5450]

If your engine is sucking trans fluid into the cylinder you have a bad clutch side crank seal .

[@bfoote1989]

@@abelvelazco5450 I ended up splitting the case. It was a bearing and I rebuilt the whole dirt bike powder coated shocks everything 100% new. It's a pretty sweet bike now re-slaved the cylinder is pretty messed up

[@abelvelazco5450]

@@bfoote1989 the main bearings don’t prevent oil from getting out of the crank case into the combustion chamber , you still likely had a bad seal for trans oil to get burned in the cylinder.

[@oxdc8141]

I love so much content kind like this but i hate if creator talking to much in video

[@GregHitchko]

Same man! If I’m trying to find out how to do something, I want to get straight to the point and don’t want to listen to BS

[@RRDfinland]

How much for that stock head?

[@GregHitchko]

Let me check if I still have it!

[@truthbetold8425]

Greg - get rid of that silly flywheel weight thats designed to tame the engine down for beginner riders.

[@GregHitchko]

Haha it's not going back on for the rebuild, but I'd love to compare it back to back to see how it changes the bike's power characteristics.

[@benjamintaft3680]

I have a RM250 manual in paper for a 95 rm250, let me know if you need anything from it

[@GregHitchko]

Thanks my dude!

[@jimmadonna1436]

That is beyond sad that she was unloved and kept outside.

[@GregHitchko]

Giving it new life now that's for sure!

[@jeffhiggins1340]

Great video but buy yourself a real impact gun

[@GregHitchko]

Thanks Jeff, a pneumatic one would be nice

[@samanthagriffin7667]

The kitchen food scale... really? 🤦🏼‍♀️

[@GregHitchko]

Thought we were cooking flywheel weights for dinner?? 🤷🏼‍♂️

[@thebeez9487]

Steahly not "Stealthy"

[@GregHitchko]

Cheers to that, can't read apparently🤣. I appreciate the correction dude

[@thebeez9487]

@@GregHitchko 😁

[@brucebanner2039]

Bro....get yourself a real impact

[@sambuvca22]

copper penny? the right tool is 3 bucks plus it works as a good key chain @ motionpro

[@user-dn5ok5fz1t]

Dude, you obviously don't know what you're doing.You need to have somebody that does know what they're doing.To help you you need a new clutch basket.